Automated high-throughput seed sample handling system and method

ABSTRACT

A method and apparatus for processing seed or seed samples includes an autonomous sorter which sorts seed by pre-programmed criteria. Optional features can include a counter to autonomously ensure the correct number of seeds to a seed package, a cleaning device, a sheller, and a label applicator. A conveyance path, controlled automatically, can move the seed to appropriate and desired stations during the processing while maintaining the sample segregating from other samples. Validation of the sample can be pre-required and information about the sample can be derived and stored for further use.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Divisional Application of U.S. Ser. No. 10/731,208filed Dec. 9, 2003, which is a Divisional Application of U.S. Ser. No.09/776,403 filed Feb. 2, 2001, now U.S. Pat. No. 6,706,989, hereinincorporated by reference in its entirety.

I. BACKGROUND OF THE INVENTION

A. Field of the Invention

The present invention relates to handling seed, and in particular, toautomatic processing of previously harvested seed samples used in plantbreeding programs and applications.

B. Problems in the Art

As is well known in the art, corn breeding is an arduous science. Theharvesting, handling, and ultimate processing of corn seed samples intopackages is an exacting and labor intensive process. Strict standardsexist with regard to the same. One important part is the harvesting andhandling of breeding seeds. Not only is it crucial to keep track of suchthings as particular characteristics of the seeds (e.g. genotype, inbredidentification, where they were grown); each seed and each seed samplemust be carefully handled and evaluated, so that there is a highprobability the selected seeds will germinate and so that there is nocontamination of the set of seeds comprising the sample of seeds. Onlythose that meet certain criteria (e.g. undamaged, not diseased, correctcharacteristics) are used for further breeding activities.

For example, breeding, product development, and productcharacterization/commercialization processes require the production,evaluation, and use of many samples of corn (Zea Mays). Each sampleconsists of from one to many ears of corn. Typically, corn plants aregrown to maturity in nurseries, and then conditioned and processed inthe following separate steps: artificially dried in seed dryers,shelled, the seed cleaned and sized, and then packaged either forreplanting or shipment to other locations for yield testing orevaluation for additional breeding crosses. This process must beconducted so that there is no intermingling or cross-contamination ofseed samples, and must include a step for removing such things as inertmatter, excessively small or large seed, and damaged or diseased seed.This process, from shelling through packaging, is currentlysubstantially manual in nature, and processes samples at the rate of15-20 samples/person-hour. Each of the steps is usually conductedseparately, with non-integrated devices or machinery.

For example, seed samples are conventionally processed as follows. Cornears are harvested in the field and then placed in plastic mesh bagshaving some identifying tag. These bags are then dried in dryer bins.When dry, they are manually unloaded and run through a sheller. Theshelled seed is then cleaned using any of a number of different methodsranging from cylindrical screens made out of hardware cloth, to flatoscillating screens, or plastic buckets with screen bottoms.

All of these approaches seek to remove small seed and debris. Thesemi-finished seed is then manually inspected and any damaged ordiseased kernels are removed. The seed is then packaged and shipped toother nurseries or counted out into small envelopes in preparation forplanting.

All of the seed transfers between pieces of equipment occur by hand, thecleaning operation is performed manually, and the transfer to a packageoccurs manually. The current manual system requires about 8 people and 8hours to shell 1000 samples, each containing 8 to 10 ears. If a nurseryhas to process 4000 samples per day, it will need either 2 shellersoperating for two 8 hour shifts with 16 people per shift, or 4 shellersand 32 people to staff the process for one 8 hour shift. It is asignificant management challenge to hire, train, and manage 32 part timeemployees and to make sure that no errors or mistakes occur because offatigue, operator error, or boredom.

It can therefore be seen that there is a significant need in the art foran improvement in such processing of seed corn. Similar methods are usedto process other types of seed samples. It is therefore a principalobject of the present invention to provide a seed conditioning processand system which improves over the state of the art. Other objects,features and advantages of the present invention include a conditioningprocess and system for seed samples which:

-   -   (a) provides significant improvement in the time needed to        process seeds;    -   (b) maintains or exceeds quality of current processing methods;    -   (c) reduces labor costs;    -   (d) reduces errors or mistakes;    -   (e) can be substantially or completely automated;    -   (f) is flexible, can be varied according to need, and allows        integration of a plurality of seed processing or conditioning        functions;    -   (g) provides good discrimination between desirable and        undesirable seeds;    -   (h) allows for accurate tracking and identification during and        after processing of the seeds;    -   (i) is economical and efficient; and    -   (j) is durable;    -   (k) allows non-destructive, careful handling of seeds and seed        samples;    -   (l) allows communication between those that need to use seed        samples and the processing of the samples to assist in the        efficiency and intelligence of a wider system involving use of        the seed samples;    -   (m) can include automatic notification or communication of        intelligence about the processing and the seed samples to those        wanting or needing to know such information;    -   (n) allows for automated or machine assisted decisions to assist        in efficiency and accuracy of the seed sample processing.    -   (o) Is integratable with a number of functions or processes to        reduce labor, expense, time and errors in processing seed and        seed samples.

These and other objects, features, and advantages of invention willbecome more apparent with reference to the accompanying specificationand claims.

II. SUMMARY OF THE INVENTION

A seed or seed sample handling process and system includes automatedhandling of previously harvested seeds, by assigning or validating anidentifier to a set of seeds, automatically performing one or moreoperations on the set of seed, and accumulating on end product andstoring information about the end product correlated to the identifier.Optionally, the end product can be selected seeds of the set of seedsmeeting certain pre-defined criteria. A possible feature of theinvention includes validating the identity of a harvested seed sample,tracking the sample through a seed conditioning process, and ensuringits purity and identity as it is packaged. A still further possiblefeature of the invention includes deriving information about the seedsample during the conditioning process which can be correlated to thesample. As an example, a discrimination device or method can be used toanalyze the seeds and discriminate between them or derive acharacteristic of the seed, such as based on moisture. Optionally, thederiving information can be added to a pre-existing knowledge base aboutthe seed from which the sample is taken and conditioned.

The apparatus, system and method can be substantially automated and cancondition one batch at a time from start to finish, or conditionmultiple batches serially. Still further automated functions can beadded. The conditioning system and the derived information can be usedin a substantially automated system of conditioning seed samples andadministrating an inventory of a plurality of seed samples; validatingrequests for certain seed samples, confirming and maintaining purity andidentification of requested samples, and packaging and preparingrequested samples for shipment to designated recipients.

III. BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagrammatic view of a system according to a preferredembodiment of the invention.

FIGS. 2A-C is a flow chart of a method according to a preferredembodiment of the invention.

FIG. 3A is a process and information flow diagram according to anembodiment of the present invention.

FIG. 3B is diagram illustrating the interaction of data according to anembodiment of the present invention.

FIG. 4 is a diagram showing database tables of the local databaseaccording to an embodiment of the present invention.

FIGS. 5A and B is a diagram illustrating the parallel relationshipbetween seed processing and information processing according to anembodiment of the present invention.

FIG. 6 is a perspective view of an embodiment of the system of FIG. 1.

FIG. 7A is a top plan view of FIG. 6.

FIG. 7B is a right side plan view of FIG. 7A.

FIG. 7C is front plan view of FIG. 7A.

FIG. 7D is a left side plan view of FIG. 7A.

FIG. 8 is perspective view of an embodiment of a control enclosurecabinet of FIG. 4 and certain internal components.

FIG. 9 is an electrical schematic of AC power distribution for thecontrol circuitry of FIG. 8.

FIG. 10 is an electrical schematic of DC power distribution for thecontrol circuitry of FIG. 8.

FIG. 11 is an electrical schematic of input wiring for the controlcircuitry of FIG. 8.

FIG. 12 is an electrical schematic of output wiring for the controlcircuitry of FIG. 8.

FIG. 13 is an electrical schematic of a seed counting subsystem for thecontrol circuitry of FIG. 8.

FIG. 14 is a diagrammatic view of pneumatic power source for use withthe control circuitry of FIG. 8.

FIG. 15 is a diagrammatic view of pneumatic lines in the system of FIG.3.

FIG. 16 is a diagrammatic view of product line vacuum control lines forthe pneumatic lines of FIG. 15.

FIG. 17 is a diagrammatic view of the pneumatic cylinder control linesfor pneumatic cylinders for the system of FIG. 3.

FIG. 18 is a block diagram showing the relationship between various userinterface screens of one embodiment of the present invention.

FIG. 19A is a graphic user interface (GUI) presented to an operator of asystem according to FIG. 1 permitting a user to select particular typesof seed or products.

FIG. 19B is a GUI showing the system settings.

FIG. 19C is a GUI of system settings for a particular type of seed orproduct showing the accompanying processing times.

FIG. 20 is a GUI of set up screen to initialize the system for a certaintype of seed or product.

FIG. 21 is a GUI for hardware set up for the system.

FIG. 22 is a GUI for a run screen for the system.

FIG. 23A is a GUI for a bar code format and label set up for the system.

FIG. 23B is a GUI for label format for a box which will hold one or moresamples processed by the system.

FIG. 24 is a GUI illustrating content of one or more boxes.

FIG. 25A is an example of a printed label for a set of “clean” orselected seeds from the processing of the system.

FIG. 25B is an example of a printed label for a set of “dirty” ornon-selected seeds from the processing of the system.

FIG. 25C is an example of a label for a box adapted to hold one or moreof the clean or dirty sets of seeds processed by the system.

FIG. 26 is a perspective view of a seed cleaner station according to thesystem of FIG. 3.

FIG. 27 is a front elevation of FIG. 26.

FIG. 28A is an enlarged isolated side elevation of a collection funneland actuatable slide gate of FIG. 26.

FIG. 28B is a still further enlarged perspective view of a slide gatefor the collection funnel of FIG. 28A.

FIG. 28C is a sectional view taken along lines 28C-28C of FIG. 28B.

FIG. 29 is a perspective view of a self-cleaning seed cleaner with first(scalping) and second (sieving) sizing screens.

FIG. 30A is a side elevation view of the embodiment of self-cleaningseed cleaner of FIG. 29.

FIG. 30B is similar to FIG. 30A but shows a screen cleaning function forthe embodiment of FIG. 29.

FIGS. 31 and 32 are diagrammatic views illustrating the principal ofoperation of the embodiment of FIGS. 30A and 30B.

FIG. 33 is a side elevation view of FIG. 29 showing the seed cleaners ina lowered position.

FIG. 34 is identical to FIG. 33 but showing the seed cleaners in anupward or cleaning position.

FIG. 35 is an isolated perspective view of the actuators and linkagethat operate self-cleaning functions of the cleaner of FIGS. 33 and 34.

FIG. 36 is an alternative embodiment to FIG. 34.

FIG. 37A is a perspective view of an embodiment of a seed cleanerstation.

FIG. 37B is an enlarged isolated perspective view of the cleaner feederfor the station of FIG. 37A.

FIG. 37C is an enlarged isolated perspective view of a seed counterattached to the outlet of the seed cleaner of FIG. 37A.

FIG. 38 is a diagrammatic perspective view illustrating the functions ofa color sorter.

FIG. 39 is an enlarged isolated perspective view of a sorter bucket fromthe outlet end of the sorter of FIG. 37A.

FIG. 40 is a side elevation view of the sorter feeder and sorter seedchute of FIG. 37A.

FIG. 41 is a side elevation of the color sorter station of FIG. 37A.

FIG. 42 is an enlarged perspective view of a swap valve and sorterfunnel of FIG. 41.

FIG. 43 is an enlarged elevation taken at line 43-43 of FIG. 41.

FIG. 44 is an isolated top plan view of a slide gate of the swap valveof FIG. 42.

FIG. 45 is an isolated elevation view of the slide gate of FIG. 44.

FIG. 46 is a perspective view of an embodiment of a bagging station ofthe system of FIG. 37A.

FIG. 47 is a front elevation of FIG. 46.

FIG. 48 is a side elevation of FIG. 46.

FIG. 49 is an enlarged perspective view of the working components of thebagging station of FIG. 46.

FIG. 50 is a still further enlarged front elevation of FIG. 47 showingcertain internal components in ghost lines.

FIG. 51 is a side elevation of FIG. 50.

FIG. 52 is an isolated enlarged perspective view of a collection funneland actuatable door for the bagging station of FIG. 46.

FIG. 53 is a side elevation of FIG. 52.

IV. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT A. Overview

For a better understanding of the invention, an embodiment will now bedescribed in detail. Frequent reference will be taken to the drawings.Reference numerals and letters will be used in the drawings to indicatecertain parts and locations in the drawings. The same reference numeralsor letters will indicate the same parts or locations throughout thedrawings unless otherwise indicated.

B. General Environment

The embodiment will be discussed in the general environment ofprocessing seed corn for breeding purposes. The embodiment wouldpreferably be housed in a suitable building, in a controlledenvironment, preferably shielded from outside environmental conditions.

C. Overall System Apparatus and Information Structure

FIG. 1 diagrammatically illustrates a corn seed processing/conditioningsystem 10. A controller 12 (e.g. RunTime RT-505 from Ann ArborTechnologies of Ann Arbor, Mich.) is operatively connected to a computer14. Together controller 12 and computer 14 operate with system 10 toprovide an automated production line for taking ear corn that has beenbagged into mesh bags 16 and dried, each including a removable machinereadable tag 18, sometimes called a harvest tag, (here bar coded), andperform a variety of functions to process seed from the ear corn to thepoint where the seed corn is bagged into shipping bags 20 bearingmachine readable labels 22 in condition for further use, e.g., forcontinued use in corn breeding programs.

Ear corn samples from particular field plots are bagged. Bar codes aregenerated by known methods with identifying information about eachsample. The identifying information is correlated to a data base formatthat can be used in maintaining an overall seed inventory and controlsystem for a plant breeding program.

Instead of individual, manual handling and conveyance of each sample toprocess it for further use, system 10 automatically processes orconditions the sample seed.

But additionally, in parallel, system 10 validates each sample, keepstrack of each sample, and can gather additional information about thesample. This additional information can be used to update the databaseabout the sample, and can be transferred and used by other systems.

As a result, the objects of the present invention are achieved. Samplesare conditioned in less time, with less chance for error, whileautomatically tracking and gaining additional information and knowledgeabout the sample.

FIG. 1 illustrates diagrammatically an example of a system 10, includingvarious components and stations in a continuous processing line. Thecomponents can vary in number and function.

Programmable controller 12 is in electrical communication with a numberof actuators, sensors, and computer 14 via an Ethernet network(indicated diagrammatically by reference number 46). Controller 12includes a display and a touch screen for data entry. Controller 12, incombination with computer 14, controls much of the operation of system10, and allows operator initialization and adjustment of certainparameters.

System 10 is linked not only by the conveyance path 29/33/35 fromstation to station, but also a combination of electrical and pneumaticcircuits. These will be discussed in more detail later. Generally andfor purposes of reference, system 10 uses air transport tubes to conveybatches of seed from station to station. Electrically controlled linevacs supply pressurized air to the transport tubes. The electricallycontrolled line vac actuators will be referenced by LV1, LV2, LV3, LV4,and LV 6. Air transport is not the only way to move seed samples, but isconsidered preferable, and perhaps the best presently known way forconveying seeds for a number of reasons. Among them are it is clean,conveys seed at reasonably high speed but with minimal trauma, is easyto install and plumb, has no moving parts for less complexity and morereliable and durable operation, is easier to fix and maintain, and ishighly adaptable to different space and path requirements. Relativelysmall diameter, flexible, clear tubing can be used for the conveyancepaths.

Gates and doors are operated by electrically controlled pneumaticactuators (solenoid operated) referenced by PN1, PN2, PN3, PN4, PN5,PN6, PN7, PN8, PN9, PN10, PN11, PN12 and PN13. The actuators havetwo-way ported cylinders, they are actuatable to one of two states byplacing higher pressure on one side of the cylinder ram and creatinglower pressure on the other side relative to one state or the other.Many of these actuators hold gates or doors in a normally closed state,but when actuated, move a gate or door to an open state to create apathway for seeds to pass. Several air jets are operated by electricallycontrolled actuators referenced by AJ1, AJ2, and AJ3. Examples ofpneumatic cylinders that could be used are Models 6-DP-1-M, 6-DP-2-M, or6-DP-3-M from Humphrey Products Company of Kalamazoo, Mich.; or model2A710 pancake cylinders from Speedaire, for screens 260A and B ofcleaner 30.

By referring to FIG. 8, it can be appreciated that controller 12controls the actuators as follows. Controller 12 communicates withsolenoids associated with each actuator by sending an electrical signalwhich energizes the solenoid. The solenoid energizes its actuatorsupplying compressed air to a pneumatic cylinder (two-way) that has twostates. The compressed air pushes the ram of the air cylinder. Thismechanical force is then usable to open and close doors or gates, oropen and close pathways for compressed air.

The electrically controlled actuators can have electrical sensors (e.g.Model BIM-PST-AP6X-V1131 inductive sensors from Turck of Minneapolis,Minn.) associated with them which inform controller 12 of the state ofthe actuator. Thus controller 12 can monitor whether a gate or door isopen or closed. These sensors are referenced by S1, S2, etc. the sensorreferences corresponding to the pneumatic actuator references.

Computer 14 and controller can include a display and a data entryinterface, e.g. touch screen or keyboard. Computer 14 could reprogramcontroller 12, or controller could be directly reprogrammed. An operatorcould therefore quickly change such things as the timing of operation ofthe various controller-controlled components of system 10. Controller 12would be programmed to send digital instructions at appropriate times toany of the electronically controllable components in system 10.

Software could time the operation of the various components so that theydid not have to continuously operate, even though no ear corn or seedwas at the particular station. On the other hand, software could controlthe components to allow more than one batch of seed to be in process,but in different sections of, system 10 at the same time.

Bar code reader 24, as well as information from devices 36A-E, isinterfaced to controller 12 which communicates with computer 14 formanipulation or storage of information via Ethernet network 46.

The above-described combination provides intelligence to controller 12and computer 14 for operation of system 10. System 10 is therefore notonly highly automated and autonomous, it is flexible. Safeguards can beprogrammed into system 10. For example, sensors can inform controller 12that a certain gate is ajar. The programming can stop processing untilthe gate is checked. Other checks, error alarms, and monitoring can bebuilt into system 10.

Of course, system 10 must be initialized prior to operation. Thisincludes calibration. For example, cleaner 30 may have to be adjustedfor different sizes of seed samples. Color sorter may have to beadjusted for different types of seeds (a color indicating a defect forone type of seed may be the color of health of another seed). Timing canbe adjusted for different numbers of seeds per batch. For example,programming can wait for a pre-set time period for a function in one ofthe stations to be complete. This time period may need to be extendedfor larger batches of seeds or shortened for smaller batches.

The first station is sheller 28 (see FIG. 1). As is well known in theart, sheller 28 receives ear corn as input and mechanically separatesthe seed from the ear. Bags 16 are brought to sheller 28. A bar codereader 24 is used to read the tag 18 associated with a bag 16 tovalidate the information that has been encoded in a bar code on tag 18.This validation process, made possible by the pre-existing knowledgebase in a data base, essentially authorizes the process of that batch ofseed through the processing line.

A conveyance system moves the seed from the output of sheller 28 to thesecond station, here referred to collectively as cleaner 30. Debris,some damaged seed, and other unwanted material is separated from goodseed. Cleaner 30 can be a screen cleaner. Other methods or devices couldbe used. As indicated at FIG. 1, a plurality of devices or functionscould be included in and/or conducted by cleaner 30. Examples showninclude scalping the seed (see 30B) and a preliminary sizing sorting ofthe seed (see 30C).

A conveyance system would move the batch of seed from the output ofcleaner 30 to the third station, referred to generally here as sorter36. FIG. 1 illustrates a color sorter, such as are known in the art.Sorter 36 functions to select desirable seed. For example, a colorsorter attempts to use color or gray scale to discriminate betweenhealthy seeds and diseased or damaged seeds. Some undesired seeds makeit through cleaner 30. Sorter 36 attempts to remove them.

A conveyance system then moves the batch of seed to the fourth station,bagger 32, where the seed selected by the sorting system is accumulatedand bagged for use.

As shown in FIG. 1, additional functions can be performed on the batchof seed in the system. Certain characteristics of the seed can bemeasured. Examples are moisture of the seed (see 36B), temperature ofthe seed (see 36B where the temperature compensation may be used todetermine moisture) and weight of the seed (see 36C). The batch ofselected seed can also be counted (see 36E). All of these functions areaccomplished autonomously.

FIG. 1 shows an near infrared (NIR) analyzer 36D that possibly couldalso be used to derive other characteristics about the seed. Examplesinclude protein levels, starch levels, and other information. NIRanalysis is well known in the art. Information derived from such sensorsand analyzers, the examples of which are shown at 36B-E, can becommunicated to the computer which can correlate the information withthe batch of seed sample in the database.

The computer can generate labels 22 which can add derived information tothe label, here including a bar code. The computer can also generate alabel 45 for a box 44. The bar code for box 44 could contain informationabout which bags of seed samples are in the box, shipping information,and/or other information.

FIGS. 2A-C illustrate one specific methodology that can be utilized withsystem 10. This method could be implemented through appropriate softwarewritten in appropriate language for use by controller 12 and computer14. It will be discussed in more detail later. Of course, variations canbe used.

FIGS. 3A and B, 4 and 5 diagrammatically illustrate the information flowstructure and parallel flow of information and product through system10. Note how system 10 has in real time validated it is processing theright sample and immediately adds to the knowledge base regarding thesample as it is conditioned for packaging and shipping.

The central database can run as an application on an enterprise-wideLAN. A database utility takes information and puts it into MicrosoftEXCEL files (or comma separated values (CSV) files) into a localMicrosoft ACCESS database files, copied from a remote server. A smallapplication communicates with controller 12 and gives information backto controller 12; and lets it process. When through, system10/controller 12 picks up and sends information and time/date (andsequence #) to computer 14 which can generate a label.

D. Specific System Apparatus and Example of Processing

FIGS. 6-7D give an assembled view of stations 28, 30, 36, and 40 and theconveyance mechanism between them. A control enclosure 50 (approx. 6 ft.tall by 6 ft. wide by 2 ft. deep NEMA 12 enclosure) for electrical andpneumatic circuitry is also shown, along with raceway 52 from enclosure50 to distribute that circuitry to the stations and the controller.

FIGS. 8-17 illustrate some of the contents of enclosure 50 wheninstalled as well as the electrical and pneumatic circuits for system10. These figures give details of one way to build these sub-systems.

FIGS. 18-25C illustrate examples of graphic user interfaces (GUIs) suchas could appear on display 13 of controller 12 or a display of computer14 related to initialization and set-up of system 10 and formatting oflabels printed for samples and boxes for samples that are processed bysystem 10.

FIGS. 26-53 illustrate stations 30, 36 and 37, and associatedcomponents, in more detail.

An exemplary specific seed sample conditioning process, in accordancewith the programming of FIGS. 2A-C, will now be described with respectto the specific apparatus shown in FIGS. 6-53. Steps of the programmingof FIGS. 2A-C will be called out while referencing each processingstation and/or parts thereof with reference numbers.

The different stations and the devices and methods used at the stationsin system 10 can vary. For example, one device may be able to adequatelyperform the functions accomplished by cleaner 30 and sorter 36 inFIG. 1. Some seed may not need to be shelled. Counting may not berequired, or any evaluation like that which NIR analyzer is capable of.

In the present embodiment, however, related to processing andconditioning of corn seed samples for corn breeding, shelling, some typeof cleaning and sorting, and bagging, along with at least moisture,weight, temperature and count measures are preferred.

Below are more specific details regarding components that could be usedin system 10 illustrated diagrammatically in FIG. 1.

1. Preliminary Steps/Bar Code Reader

System 10 is initialized. The operator sets parameters via keyboard ortouch screen 15 associated with computer 14 for the particular productbeing processed. For example, certain types of corn have larger kernelsthan other types. Different settings on cleaner 30 and sorter 36 may benecessary for accuracy of the system. Such settings normally will havebeen calibrated by prior testing of system 10 with the same or similartype of seed.

Electrical power (AC and DC) is presented to the controls in enclosure50 (see FIGS. 9 & 10). Pneumatic pressure is generated by the componentsillustrated at FIG. 14 (here around 90 psi at 40 CFM minimum).

Ear corn 19 can be dried in a system such as disclosed in U.S. patentapplication Ser. No. 09/498,277 to inventors Hunter, et al., bagged inbags 16, each of which can be bar code labeled as previously described(see FIG. 2A, step 51). By scanning the bar code (step 53), informationregarding the nature of the ear corn and the essential facts for recordscan be obtained by system 10 and stored in computer 14. The informationcan be displayed to an operator (step 54), and a decision can be madewhether to shell corn or ship it (steps 56, 58). Note that a workercould at this point manually inspect the ear corn and eject it.

If the ear corn is not to be shelled and processed, the process to theleft of box 58 in FIG. 2A could be followed. The ear corn 19 could passthrough or bypass system 10 until bagger 37, where the ear corn 19 couldbe placed in a new bag(s) 20, the database of computer 14 can beupdated, a label can be updated (a new label can be created by labelgenerator 42), and bag(s) 20 closed and loaded into a shipping container44, which itself could have a label describing its contents, if desired.

A bar code reader or scanner 24 (e.g. Model 5312HP from PSC, Webster,N.Y.) is positioned to read a bar code from a pre-created bar coded tag18 on ear corn bag 16. The bar code on tag 18 could contain informationsuch as indicated in Table 1.

TABLE 1 Database field Data Field 1 Bag #:       Field 2 Corn Type:      Field 3 Genotype:       Field 4 Test Plot #:       Field 5Location:       Field 6      :      

A bag 16 of ear corn (typically comprising 8 to 10 ears) can be manuallyopened and ear corn 19 poured or loaded into sheller 28.

It should be noted that bar code reader 24 can read information thatidentifies the contents of bag 16. Computer 14 therefore can store andkeep track of the relevant information about the ear corn from bag 16throughout the processing of system 10. This information can be storedin a memory, text file, or a data base as well as in a database. Theterm “data base” is to be broadly construed to refer to any set of dataregardless of its format, the type of application associated with thedata (i.e. spreadsheet, database), the type of storage used to store thedata, etc. A local database 47 can be created in computer 14 with suchidentifying information. Local database 47 can be in contact with acentral database 48.

This flow of information on an enterprise wide basis is best shown inFIG. 3B. Information including a shipping location, the year of theseeds, the season of the seeds, the location of the seed plots, a testplot identification number, seed experiment information, whether aparticular seed sample is genetically modified, and other user-definedinformation that may be stored in an enterprise wide database 48 is thenused in a local database 47. A database conversion utility may berequired, for example the enterprise wide database information may beconverted in part to a file of comma separated values or anotheruniversal format. A database utility may be required to import theinformation from a universal format to the format of local database 47.The local database 47 may be a Microsoft Access database and thedatabase utility may be a stand-alone Microsoft Visual Basicapplication. The seed processing system 10 then adds information to thelocal database 47 during seed processing, the updated local database 47Acontaining the additional information. Once the database 47A has beenpopulated with information from the seed processing system 10, thedatabase utility can then be used to extract the database to a commaseparated value (csv) file for loading into the enterprise wide database48.

The database utility creates and uses a Microsoft Access database. Asbest shown in FIG. 3C, the database is made up of an Entries table, aBox table, and a BoxNumber table. The Entries table contains all of thesample data including the box the sample is stored inn. The Box tablecontains all of the information for a box such as shipping weight andsample count. The BoxNumber table is used to build a new box entry inthe Box table. The Box ID of the Box table is related to a data field inthe Entries table. One field in the Entries table is related to the Boxidentifier of the BoxNumber table.

Also, when the harvest tag 18 is read by bar code reader 24, identifyinginformation on the bar code is immediately evaluated to ensure this bagof ear corn is authorized to be processed in system 10. This step,called validation, means that the ID of a bag 20 (from label 18) ischecked against local database 47, which has downloaded from centraldatabase 48 a list of requested samples. For example, the centraldatabase can have a complete listing of all corn breeding experimentson-going around the world. The initial validation essentially askswhether the sample ID from tag 18 “exists”, so to speak, in any of theexperiments in the central database.

If the ID (identification) does agree, system 10 is authorized toprocess that sample. If it does not agree, an error is detected. Theoperator can be notified on display 13 and controller 12 does not allowgate 62 to sheller 28 to be opened.

PC 14 makes another initial decision based on information scanned infrom harvest tag 18. It asks whether the sample type in bag 20 will runon system 10. In other words, it checks whether the settings andoperational parameters for each of the stations of system 10 are set tohandle the type or nature of the sample identified on label 18. Forexample, if the sample is a certain type of corn that needs more time inthe cleaning station than what system 10 is set for, an error or alertis given to the operator via display 13, and sheller door 62 does notopen. Thus, system 10 automatically assists in its correct and efficientoperation.

System 10 has three basic setups, primarily based on the size/shape ofthe seeds of the samples and on the volume or amount of seeds for eachsample. If the information scanned from a harvest label 18 indicates thewrong initial setup of system 10, the operator is alerted and can dealwith it then, instead of wasting the time and possibly ruining theprocessing of the sample.

2. Computer and Controller

Computer 14 is a PC-based processor with an associated display 15 andkeyboard and could be mounted in a stand or table at or near the baggingstation. Operator controls and the display allow the operator to monitorcertain aspects of the operation of system 10, as well as enter data orinstructions.

Controller 12 is a programmable intelligent digital device (RunTime PCRT-505 from Ann Arbor Technologies of Ann Arbor, Mich.). It could be aprogrammable logic controller or other PC optimizer for data acquisitionfor process control. Controller 12 has an integrated display/touchscreenuser interface 13, and is in an approximately 20″ by 16″ by 8″ enclosureon a stand at or near sheller 28. Controller 12 handles input and outputfrom and to the actuators and sensors of system 10 via I/O bases (seeFIGS. 8-11) that communicate over an Ethernet connection. An Ethernetcontroller is placed in the passive back plane of controller 12,permitting signals to be sent to and received by other I/O withincontroller 12. Input/output drivers energize relays in the back planethat open or close solenoids for the pneumatic actuators. PC 14 runs aMicrosoft Visual Basic (VB) application. PC 14 communicates tocontroller 12 using TCP/IP. PC 14 polls controller 12 for correct statusof I/O lines, essentially by one-way polling (approx. once every 50-100milliseconds), and then writes back a new status as needed. Controller12 is programmable (e.g. Think and Do language).

The apparatus of system 10 allows an automatic, continuous, real timeprocessing of seed 25, including tracking of a batch of seed that needsto be kept together, or at least precisely identified prior to, during,and after the processing.

System 10 assigns an ID string to each sample. PC 14/controller 12 pushthis string through station to station of system 10 to track eachsample. In this embodiment, up to five samples can simultaneously be insystem 10, but the invention is not confined to this. For corn seed ofconventional type, each sample takes less than one minute through system10. By tracking, system 10 knows where each sample is in system 10 atany given time, and thus knows when it is at bagging station 37 so thatit generates the correct identification label for the package for eachsample, even though multiple samples may be proceeding through system10.

By referring to the GUI's of FIGS. 18-25C, it can be seen what types ofinitialization and set-ups are possible with system 10. FIGS. 18 through19 show graphical user interfaces of controller 12, while FIGS. 19-25Cshow graphical user interfaces of PC 14. FIG. 18 shows the relationshipof a number of different screens that may be accessed from a productselection screen (see also FIG. 19A). These screens include a weightcalibration screen, a moisture calibration screen, a run screen, asettings screen (see also FIG. 19C), a manual control screen (see alsoFIG. 19B), a color sorter testing screen, and a seed counter testingscreen. Examples of timing between stations and set-ups for corn aregiven in the settings screen of FIG. 19C. Examples of the types ofoperator over-rides are given in the manual operator screen of FIG. 19B.Examples of the database fields and how they are used to create bag andbox labels are shown.

3. Automated Processing Stations

a. Sheller

If ear corn 19 is desired (and validated) to be shelled and processedfurther, the steps in the flow chart after box 56 could be followed.FIG. 2A illustrates at step 60 and step 62 if a decision is made to shipthe ear corn, the seed can be aspirated and accumulated or controlled asto rate of presentation to the next station. System 10 can check if itis free or allowed to proceed to the next process step (step 64). System10 could instruct a kernel clean process (see step 66). Aspiration couldbe integrated into sheller 28.

Sheller 28 (e.g. Model ECS by Almaco, Nev., Iowa) functions to shell earcorn 19. A variety of shellers are commercially available. Once a seedsample in a bag 16 is validated (after bar code 18 is scanned andcomputer 14 validates), the ear corn from that bag 16 are loaded into ahopper in sheller 28.

Sheller 28 is turned on and runs constantly. Sheller input gate 62 isopened by an electrical instruction from controller 12 (output BO) to anelectrically controlled pneumatic actuator (PN1) (see also FIG. 17). Theear corn for this sample batch is then shelled by sheller 28.

Non-seed (e.g. cob, stalk, leaves) can be discharged (see referenceletter D, FIG. 1) via a chute or conveyor to be discarded or otherwiseused.

Line vac LV1 (e.g. model 6063, from Exair, Cincinnati, Ohio) isactivated by controller 12. It is driven by solenoid controlledcompressed air and causes the shelled corn to be pulled from the outletof sheller 28 into air tube 60 and is conveyed first horizontally thenvertically to cyclone 71 at the top of cleaner station 30. Pressurizedair is delivered from the source (FIG. 14) via ½″ O.D. polyethylenetubing and used by the 1½″ I.D. inlet and outlet air vac.

All air tubes in system 10 are clear PVC food grade tubing, withreinforcing spiral to maintain roundness (size is approx. 1¾″ O.D., 1½″I.D., available from McMaster-Carr of Illinois). Such tubing isflexible. This makes it easy to install and allows the operator tovisually inspect the lines.

An aspirator 32 optionally could be placed at the outlet of sheller 28or integrated into sheller 28 to aspirate the seed as it is leavessheller 28. This could assist in removing dirt, debris, or otherwisepre-clean the seeds.

b. Cleaner

Controller 12 instructs cleaner 30 to perform a kernel clean cycle aftereach set of seeds is processed by cleaner 30 (see steps 66 and 68, FIG.2) to remove residual material stuck in the screens, such as describedpreviously with respect to cleaner 30A in FIG. 1. Optionally (see FIG.1), the seed can be scalped (step 70, FIG. 2) and then sieved (step 72,FIG. 2). These steps are conventional further processing steps as iswell known in the art and as discussed further later.

It again should be noted that in many of these steps along the process,undesired seed (e.g. damaged) can be automatically discarded from theprocessing path but accumulated (step 72, FIG. 2B). If it is determined,for example by manual inspection by a worker, that desirable seed is inthe bagged discard seed, it can be recovered and manually inserted in anappropriate “clean” seed bag, e.g., if additional seed is required tomeet a desired minimum seed count for the sample (step 74).

General cleaner terminology: The cleaner 30 separates desirable seedbased upon size and/or shape. Cleaner 30 consists of two perforatedmetal screens, each paired with an underlying pan. Top screen 260A hasperforations with the diameter of 26/64″ and is referred to as thescalping screen. Lower screen 260B has holes with the diameter of 18/64″and is referred to as the sieving screen. The scalping screen's holesare sized such that desirable seed pass through its holes onto itsassociated pan 262A. The sieving screen's holes are sized such thatbroken seed or undesirably small seed pass through its holes onto thesieving screen's pan 262B.

Cleaner seed flow: Seed flows from sheller 28 into cleaner feeder bucket72. When controller 12 has determined that cleaner 30 is ready toreceive seed, it opens an associated solenoid valve to energize thetwo-stage pneumatic actuator PN4/5. The first stage of actuator PN4/5opens cleaner feeder bucket door 74 to 1″. This limited opening allowsseed to flow onto scalping screen 260A at a controlled and desirablerate.

Desirable or “clean” seed flow: The desirable seed flows throughscalping screen 260A onto pan 262A and then falls from the lower end ofpan 262A onto lower or sieving screen 260B. The desirable seed thenflows off screen 260B and exits the cleaner at 266B.

Discard or “dirty” seed flow: Seed that is too large to pass throughscalping screen 260A slides across the scalping screen 260A onto lowerpan 262B associated with the sieving screen 260B. This large seed ordebris exits the cleaner at 268B. Seed that is too small is separatedfrom the desirable seed by falling through sieving screen 260B ontosieving screen pan 262B and exits cleaner 30 co-mingled with large seedand debris using 268B.

Cleaner clean-out cycle: Cleaner 30 and its associated systems have beenoptimized to avoid the cross-contamination of seed samples. The firstpoint in the clean-out cycle is for the second stage of the two-stagepneumatic actuator PN4/5 on cleaner feeder bucket 72 to open door 74completely. This allows any large debris that might potentially plug thebucket's opening to slide onto cleaner 30. The duration of the openingof each of the two stages is controlled by controller 12 and isoptimized for the products or sample sizes being run. If the bucket isnot emptied of debris and seed, it might jam and then allow seed fromthe next sample to leak onto cleaner 30 prior to the removal of theprevious sample.

Scalping screen 260A is the first screen to receive seed in cleaner 30.The seed sample from cleaner feeder bucket 72 quickly flows over orthrough the scalping screen 260A. Before scalping screen 260A can gothrough a clean-out cycle, all seed must be removed from its pan 262A.Cleaner 30 has air jets AJ1 and AJ2 that blow across the sieving screen260B and its associated pan 262B. Air jets AJ1 and AJ2 are directed atan angle such that all seed or debris are propelled off sieving screen260B and pan 262B prior to the cleanout cycle. Once pan 262A is clean,the pneumatic cylinder or actuator 288A (PN3) extends and moves pan 262Aupwards so that it strikes the bottom of scalping screen 260A dislodgingany seed or debris stuck in scalping screen 260A. This cycle is repeatedquickly at least twice to dislodge and rapidly move seed off scalpingscreen 260A. The length of time allowed for each portion of the seedsample cleaning process and then for the clean-out process is optimizedfor different materials and sample sizes and is under the control ofcontroller 12. Contaminating seed is not sensed by system 10, but in thefuture it might be possible for system 10 to know whether seed hasfinished moving through the system and whether or not contaminating seedor material remains.

Sieving screen 260B receives the material that flowed through scalpingscreen 260A and any seed or debris that is too small flows through theholes in sieving screen 260B and drops onto pan 262B. When the seedsample has been cleaned, pneumatic actuator 288B (PN2) moves sievingscreen 260B downwards onto pan 262B, thereby dislodging any seed stuckin the holes of sieving screen 260B. This up and down movement occursseveral times in quick succession while the cleaner air jets AJ1 blowany remaining or dislodged seed off sieving screen 260B. This dislodgedseed, plus any other good seed is discharged from cleaner 30 at 266B.The air jets (AJ1) are controlled by controller 12 that energizes asolenoid controlled air valve that controls the pneumatic cylinder 288A.

Cleaner 30 of FIG. 26 is a screen cleaner or sizer placed on top of ashaker table 75, such as are commercially available (e.g. Model Innova2350 from New Brunswick, Edison, N.J.—gyrational table operated at 200rpm, 1″ stroke length—counter-balanced to reduce stress). Table 75assists in the cleaning/sizing process as seeds from a sample enter andtravel over the two screens of cleaner 30.

It is to be understood that device 30 could have controller-controlledautomated equipment to perform any of the functions of cleaning theseed, scalping the seed, or sorting the seed by sieve or other method.FIG. 1 illustrates three such functions. Cleaner 30 can be any devicewhich separates seed 25 from non-seed. Non-seed material can be directedto a discharge D.

Cleaner 30 could also size and/or separate seed based on one or moresensed criteria. Criteria could include, for example, size of seedand/or shape of seed (e.g. flat vs. cylindrical). A variety of types ofsorting and sorting devices are known in the art. For example, seeds 25can be sorted by size. It might be determined that seeds of less than acertain size are not good candidates for use in breeding. Non-desiredseed or material could be directed to a discharge D where it could bedirected for further or different use.

Cleaner/scalper/sieve 30 can be either one device or a combination ofdevices. Appropriate internal or external mechanizedcontroller-controlled or gravity-based conveying devices 29 transportseed 25 between functions.

Thus, cleaner 30 is essentially a seed sizer. As is well-known, thiscould be on the basis of size or shape (e.g. flat versus cylindrical) orboth.

Importantly, cleaner 30 is self-cleaning. In many screen cleaners, someseeds and debris get caught in the openings of the screen. After eachcleaning, scalping, sieving, or sorting process, remaining seeds anddebris on the screen must be manually removed. System 10 provides forautomatic self-cleaning by continuously running shaker table 75, whichcontinuously urges anything on the screens to move, and by moving one ofthe cleaner screen and a plate against one another to dislodge anythingstuck in the screen openings.

It is important to clean cleaner 30 after each cycle, not only to removedebris for optimal sorting by cleaner 30, but also to remove any seeds.If seeds are left, they may contaminate the next sample that isprocessed. For example, one does not want to have a genetically modifiedseed from one sample inadvertently in a non-genetically modified sample.

Cleaner 30 has two air jets AJ1 and AJ2. The first air jet AJ1 ispositioned above the sieving screen 260B. The second air jet AJ2 islocated below the sieving screen 260B and above the pan 262B. Duringnormal operation, the controller 12 energizes the solenoid of the secondair jet AJ2 during the cleanout cycle, after the scalping screen's panmoves upwards driven by the action of pneumatic cylinder 288A. Thecylinder retracts and extends for three complete cycles. The controllerwaits a small time period (such as 0.5 seconds) and then the second airjet AJ2 is energized and compressed air blows across the sieving screenpan 262B for a period of time (such as 3.5 seconds). The screen 260B isdriven downwards onto pan 262B. This process is repeated three times.This process can be realized by turning on an actuator, waiting a shorttime (such as 250 ms) and turning off the actuator thus creating a rapidslapping action. During this cleanout process the first air jet AJ1 isenergized for 5.5 seconds. This combination of mechanical actions isperformed to dislodge seed from screens 260A and 260B. The blasts of airfrom the air jets AJ1 and AJ2 result in the cleaner being free ofpotential contaminant seeds.

Thus, the two stage feed rate deters overwhelming of cleaner 30 and theself-cleaning aspects deter contamination of samples.

FIGS. 27-36 illustrate an embodiment of the cleaner 30 illustrated atFIG. 26 in more detail. Flat screen 260 having a pan 262 underneath itcan be operated as is conventional. Pan 262 can be connected pivotallyto screen 260 by links 264. A rod 265 can be connected to links 264 onone side of the device and terminate in an actuator 267. Outlets 266 and268 from screen 260 and receiving pan 262 respectively would channelseeds to the respective desired locations. To clean screen 260, actuator267 would pull arm 265 to the left. This in turn would pull links 264 inthe fashion shown in FIG. 29 which would raise pan 262 up against thebottom of screen 260. Pan 262 would be configured to have a surface thatcorresponds with the bottom surface of screen 260 and serve to push anydebris or seeds lodged in perforations in screen 260 out, as shown bycomparing FIGS. 30 and 31.

FIGS. 32-34 show a dual staged flat screened sizer with a seed cleanersuch as illustrated in FIGS. 35 and 36. A housing 270 containsscreen/cleaner 260A/262A in its upper portion positioned at a 10 degreeangle relative to the horizontal plane, and screen/cleaner 260B/262B inits lower portion positioned at a 5 degree angle relative to thehorizontal plane. These angles are selected to help seed move quickerover top screen 260A, and essentially allow screen 260A to beself-cleaning; while the smaller angle helps a longer residence time forseeds on bottom screen 260B. Screens 260A and 260B are held stationaryin housing 270. Pan cleaners 262A and 262B are movable between a loweredor away position shown in FIG. 33, to a position up into abutment withthe bottom of screen 260A and 260B as shown in FIG. 34.

By referring also to FIG. 35, it can be seen that with respect to upperscreen 260A and cleaner 262A, an elongated rod 272A is connected viapins 274A and 276A to pan 262A through the side walls of housing 270 viaarcuate slots 278A and 280A. A first link 282A is connected at one endto pin 274A and a second end to pin 287A which travels in arcuate slot286A. Link 282A is pivotally fixed to the side of housing 270 at both284A.

A second link 275A is connected at one end to pin 276A and is pivotallyfixed to the side of housing 278 by bolt 292A.

An actuator 288A is mounted to an interior end wall of housing 270 atmounting plate 290 and at an opposite end has an extendable arm 290Aconnected to pin 287A at a generally intermediate position. As shown bycomparing FIGS. 33 and 34, when end 290A of actuator 288A is retracted,pin 262A is in a lowered position. When end 290A of actuator 288A isextended, links 282A and 275A are pivoted to opposite positions relativeto arcuate openings 278A, 286A, and 276A and pan 262A is brought upagainst the bottom of screen 260A to perform a cleaning function.

As with prior described embodiments, this action can occur while theentire device is oscillating or gyrating (at 200 rpm), or such movementcan be stopped during the cleaning process. It has been found that twoquickly repeated movements of pan 262A against screen 260A is preferableto one such movement as it creates some vibration to assist indislodging material from the openings in screen 260A.

Cleaning of lower screen 260B is essentially the same as described withregard to screen 260A, except that screen 260B is moved down onto pan262B. As shown in FIG. 33, the components are essentially the samealthough their configuration and orientation differs as shown. Theembodiment of FIGS. 33-35 allow sorting to occur at two succeedinglevels. Seeds are output at outlet 266B and 268B respectively for use orfurther conditioning.

FIG. 36 is similar to FIG. 33 except the position of actuator 288Adiffers.

With all embodiments, the cleaner would perform cleaning on individualscreens either through self motorization or by utilizing the movement ofeach screen itself. Therefore, the embodiments do not require anycomplicated attachment to a single drive force even if there weremultiple screens involved. Variations obvious to one skilled in the artwill be defined by the claims. For example, the embodiments can beutilized for a wide variety of screen sizes. The embodiment of FIGS.26-36 is believed to be better for smaller sized screens. Cleaner 30 isconnected to controller 12 which controls the pneumatic actuators forcylinders PN2 and 3 and air jets AJ1 and AJ2 for the self-cleaningprocess.

FIGS. 26 and 27 illustrate how desired seed or “product” is funneled toclean seed or product hopper 80 and unwanted material and seed, “dirtyseed” is funneled to dirty seed hopper 81. Actuators PN6 and PN7respectively operate slide gates that control the release of seed fromeither hopper. Upon instruction from controller 12, one or the other orboth slide gates 82 and 83 are moved from normally closed to openpositions. “Cleaned” seed is transported by transport tube 100 (byactuation of line vac LV2) to sorter station 36. The slide gates areessentially a plate with a portion big enough to block the pathwaybetween the hopper and its discharge, and another portion with anopening generally matching the size of the pathway out of the bottom ofthe relevant hopper. Its associated actuator simply slides the gate tothe desired state, closed or blocking the pathway; or open whichunblocks the pathway. This can be handled well with a linear doubleacting pneumatic cylinder.

Normally about 5%-10% of the sample is discharged as “dirty”, mostlycomprising broken seeds or foreign material. Thus a substantial majorityof the sample is passed as “clean” or selected product.

Note that a perforated section 108 of tube 100 (see FIG. 27) could beused below bucket 80. This 4″-5″ section could be made of galvanizedmetal, 1½″ I.D., 14 gauge, with several hundred 3/32″ offset holes 109.This would assist the movement of seeds through the respective air tube,especially where relatively large volumes of seed accumulate, forexample, possibly at the cleaner bucket and at the color sorter bucketfor good product. It allows easier air movement into the conveyance tubeto transport the seed sample to its next destination. Otherwise, the useof air-tight tubes and gates may not provide sufficient volume andvelocity of air to fluidize the seed. Perforated sections like section108 could be used at other parts of system 10, particularly whererelatively large amounts of seed need to be conveyed.

c. Color Sorter

Once processed to step 72 (see flow chart of FIG. 2), the seed isaccumulated (step 74) and a kernel clean process is instructed bycontroller 12 (steps 76 and 78). This self-cleaning could includeoperation of an air jet AJ3 to rid color sorter 36 of any seeds thatmight be lodged or otherwise remain in color sorter 36. Active cleaningof color sorter 36 is accomplished by an air jet AJ3 at the funnel 103and chute 104 (see FIGS. 37B and 40).

Controller 12 can operate pneumatic conveyor 33 to move seed 25 to thestep of color sorting at reference numeral 80 in FIG. 2B. Color sortingcan be used to remove diseased, damaged, or otherwise undesirablekernels based on color or other differences that can be discriminated ina video imaging of at least a portion of a seed. The process of colorsorting alone can eliminate a significant part (estimated at half) themanual labor involved in such processing of corn seed.

Non-destructive evaluation and/or automated counting (step 82) can takeplace. Non-destructive evaluation can include, for example, the types ofsensing previously described; e.g. measurement of moisture, weight, oilcontent, etc. Database (see step 84, FIG. 2B) in a computer system caninstruct the process regarding the type and amount of seed that isdesired (step 86). The system can compare the actual count (step 82) tothe requested seed count (step 88) as well as check whether moisture orother characteristics is/are acceptable (step 90). For example, NIRanalyzer 36D of FIG. 1 could be used to select only high oil contentseed 25 based on NIR sensing and sorting similar to the color sortingshown in FIG. 3.

Air transport 100 (FIG. 337B) is another pneumatic conveyor, with a tubeoperatively connected to a controller-controlled pressurized air source34 that can lift seeds 25 vertically.

Cleaned seeds are lifted to color sorter cyclone 101 and drop by gravityinto color sorter feeder bucket 102. Upon instruction of controller 12,color sorter feeder bucket actuator PN8 opens hinged door 110 (FIG. 40)which opens a pathway for the seeds to fall into sorter feeder funnel103, and then into color sorter seed chute 104.

Color sorter 36 is commercially available model ScanMaster 200 IE fromSatake, Houston, Tex. Color sorting is well known and has been used tosort such things as rice, peanuts, cubed vegetables, beans, potatochips, and frozen foods. It uses a digital imagining device or camera 38to discriminate, on a seed 25 by seed 25 basis, whether or not to accepta seed 25 based on information discerned by imaging at least portions ofeach seed 25. Model 200 IE normally uses a vibratory feeder as an inputof materials into the color sorter. However, color sorter 36 insteaduses a feeder bucket 102 with a gate 110 controlled by controller 12.

The basic principles of operation of a color sorter are illustrated atFIG. 38. A conveying mechanism 348, controlled by acontroller-controlled actuator 350, receives incoming seeds 25 fromsource 333. The plurality of seeds 25 are presented serially and atgenerally uniform velocity along some type of conveyor 348 or path (seeseeds 25A-H in FIG. 38). Color sorter 36 (FIGS. 37A-C) directs seedsfrom feeder 102 into a plurality of generally parallel paths orchannels, so that sorting of each channel can occur simultaneously forgreater throughput. In comparison, FIG. 38 shows just one path orchannel for simplicity of illustration. Color sorter 36 (FIGS. 37A-C)also uses gravity to convey the seeds through the channels, see seedfunnel 103 and ramp 104 in FIGS. 37C and 40. Once the channels areformed, seeds actually fall in free space for a time. The structure ofcolor sorter 36 encourages a seed trajectory of a consistent speed.Color sorter 36 is set up to handle on the order of 200 seeds perchannel per second. Funnel 103 concentrates the seeds accumulated infeeder bucket 102 into four principal channels, although the ScanMasteraccommodates 10 channels. This is because it is believed a steady flowgives better results than an intermittent flow. This results in athroughput on the order of 800 seeds per second. For typicalapproximately 2000 seed samples, one sample can be color sorted inapproximately 5 seconds. This represents a very substantial savings intime over manual inspection of 2000 seeds.

Referring back to FIG. 38 for illustration purposes, a light source 354of substantial intensity illuminates the seeds. A digital video imagingdevice 358 captures images of the illuminated seeds. A light bar control356 and video processor/controller 360 are operatively connected todevices 354 and 358 to illuminate and digitally scan seeds 25 as theyserially pass thereunder. The video scans are evaluated by processor 360(and computer 14) against predetermined criteria based on visualcharacteristics of seed 25. For example, diseased portions of harvestedcorn seed is usually darker in color than that non-diseased seed. Byappropriate calibration, seed 25 can be visually discriminated bycomparison to adjustable color or darkness/lightness thresholdsprogrammed into the system.

In color sorter 36 (FIGS. 37A-C), two sides of the seeds can beilluminated as they fall in free space (two light sources are used, oneabove and one below the channels of falling seed). Two CCD imagers, oneabove and one below the channels, can be used to examine two sides ofthe seeds to more completely check for undesired seeds.

Referring back to FIG. 38 for illustration purposes, acontroller-controlled deflecting ejector 366 is positioned downstream ofimaging device 358. By coordination with imaging device 358, a ejectionactuator 368 can operate ejector 366 to cause identified non-desiredseed 25 to be physically deflected from conveyor 348 (see arrow 364relative to seed 25D in FIG. 38). It is calibrated to take into accountthe time between detection of a bad seed and the time to fire theejector based on known velocity of the seeds. Ejector 366 could be anair jet (one per channel) and ejection actuator 368 a source ofpressurized air. The dwell time of the air jets would be adjustable.More dwell time would increase the probability of propelling a seeddesignated for discard out of the falling stream of seeds, but alsorisks ejecting seeds that are not designated to be ejected. Adjustmentscan be made based on empirical testing.

Alternatively, ejector 366 could be a pneumatic, hydraulic orelectro-mechanically actuated arm or finger that would physically knockor push a ejected seed 25 from conveyor 348, as controlled by actuator368.

Non-ejected seeds 25 would pass ejector 366 without deflection and bedirected by conveyor 348 to device 36A, as shown in FIG. 1.

It is to be understood that color sorter 36A could take on manyconfigurations. Color sorter 36 of FIGS. 37A-C and 39-45 uses gravityand seed chutes to send seeds moving down separate parallel paths andthen into a free fall in those aligned paths. Light bars on both sidesof the dropping seeds illuminate two sides of the sides. The CCD imagerline scans and compares its pixel values to thresholds. Softwarerecognizes what is probably a seed versus air. If a programmed thresholdis exceeded, color sorter identifies which seed, and knowing itsapproximate velocity, operates an air jet (AJ3) at the appropriate timeto deflect an undesired seed to discard. Other configurations andmethodologies could also be used.

Selected (non-ejected) seeds fall into color sorter bucket 106 (FIGS.37C and 41). As shown in FIG. 37A, 37C, and 41, before they reach bucket106 the seeds pass through counter 105. Counter 105 is a granular mediasensor model GMC from Jacobson-Holtz Engineering, Perry, Iowa. It canprovide controller 12 (via a mV signal) a reasonably accurate count(approx. +/−10%) of the number of seeds passing by. It provides countinformation for the batch being processed. The count is accurate enoughto tell if there is enough seed in the processed sample to ship to meeta request. As a default, system 10 requires a minimum 500 seedthreshold.

A variety of such counters are available off the shelve. One examplemeasures the dielectric constant of a gap between two sensingelectrodes. Depending on the presence and amount of seed between theelectrodes, a dielectric constant is sensed compared to when no seed isin the gap. When some seed is detected, it is considered an “event”. Thechange of dielectric constant can be calibrated based on the number ofseeds by assigning a number of pulses to the sensed dielectric constant,and thus a total seed count for different samples can be derivedautomatically and quickly by comparing the number of pulses to thecalibration. Photo-optical counters are another example.

Discard or “dirty” (ejected) seed separated by color sorter 36 fall intoa “dirty” seed funnel 112. The position of sway valve 113 (FIGS. 41-44)determines if this collected “dirty” seed is sent via pneumatictransport tube 120 and line vac LV5 to trash cyclone 121 (see FIG. 15),or via transport tube 118 to bagging station 37. Swap valve actuatorPN11 operates a slide plate 114 which has two openings 115A and B fromwhich two tubular connectors extend, to which are attached air transporttubes 120 and 118. In a trash cyclone position, plate 114 is slid to aposition that allows discard seed access to transport tube 120. In abagging position, plate 114 is slid to a position that allows thediscard seed into transport tube 118. This is selectable by the operatorand under control of controller 12. One opening 118 in fixed plate 119is in fluid communication with line vac LV5. Slide plate 114 is slidableby actuator PN11 to either align its opening 115A or 115B with opening118 in fixed plate 119.

Note also that a diverter valve 116 is positioned just ahead of(upstream of) counter 105. Diverter valve actuator PN9 can be operatedby controller 12 to block the pathway of “good” (non-ejected) seed fromcolor sorter 36 and instead direct such seed into diverter drop tube117, where it will fall into dirty seed funnel 112. This can occur ifcounter 115 indicates a seed count threshold has been exceeded. Suchdiverted, but otherwise “good” (not “dirty”) seed will be handled withthe discard or “dirty” seeds as previously described.

A slide gate 107 at the bottom of color sorter bucket 106 is controlledby actuator PN10 (under controller control) when controller 12authorizes bucket 106 to be dumped. See FIGS. 37A, 37C, and 39.

Other characteristics of a seed 25 could also be remotely,non-destructively obtained in real time under controller control as theseed 25 is being conveyed in system 10. As shown in FIG. 1, a nearinfrared spectroscopy device 36D could be used not only to measuremoisture, but a variety of other characteristics. See U.S. Pat. No.5,991,025, to Wright, et al., incorporated by reference herein. Otherexamples are nuclear magnetic resonance (NMR), and Roman spectroscopy.Examples of characteristics that can be non-destructively sensed inessentially real time include but are not limited to oil content,protein content, moisture, color chemical properties, genetic make-up,width, length.

e. Bagger/Labeler

If the answer to boxes 88 or 90 of the program of FIG. 2 is “no”, theprocess (FIG. 2B) loops to provide the seed count and determinesmoisture level (step 92) prior to automatically filling a bag (step 94)with the processed seed of desired characteristics.

Database 96 provides the necessary information to create the appropriatelabel (step 98) and/or the appropriate box and/or shipping label (step100).

System 10 and its methods of operation removes a substantial amount, ifnot most, of the manual aspects of such seed handling and processing. Itcan represent up to a four-fold increase in samples processed each daywhile using much less labor. The invention overcomes disadvantages ofthe prior art by dramatically reducing the labor required and byallowing a continuous flow of seed samples through the process under thecontrol of a controller linked to a PC-based user interface anddatabase.

System 10 provides for a speedy processing of seed. System 10 allows forintegration of several functions under automatic control. System 10isolates seed, as needed, during the processing. It also reduces errors,particularly erroneous mixing between samples.

FIGS. 46-53 show a bagger station 37. Desired product from color sorter36 is pneumatically conveyed via air transport tube 140 to baggingcyclone 141, and then drops into bagging product bucket 122 (FIGS.49-51). Two measurements are taken in bucket 122.

Seed sample weight can be obtained (see device 36C in FIG. 1). Loadcells 123 (Model RL1010, 15 Kg load cell, 2 mV/V, with 4 channel summingbox 4LC100-SEE from Rice Lake Weighing Systems, Rice Lake, Wis.) supportbucket 122 on the framework of bagger station 37. Load experienced byload cells 123 is translated into weight of the seed (weight of bucket122 is subtracted) and is read by controller 12.

Moisture content is be measured by a controller-controlled device 124. Avariety of methods could be used to obtain such a measurement remotelyand non-destructively in essentially real time. One example is aphoto-acoustic method, such as is well known. Another example is use ofnear infrared (NIR) spectroscopy, such as shown and described inco-owned issued U.S. Pat. No. 5,991,025 to Wright, et al.

Moisture probe 124 (FIG. 49) is a capacitive moisture probe, such as isknown in the art and mounts through the back of bucket 122, extendinginto its interior so that it can extend into the seed that accumulatesthere. An interior bucket (see reference numeral 129 in FIG. 50) fillsup first to get uniform volumes of seed from measurement to measurement.After interior bucket 129 is filled, additional seed spills out intobucket 122. Other such methods are possible.

By monitoring moisture of each sample accumulated at bagging station 37,system 10 can alert the operator on controller display 13 if a sample istoo wet (e.g. above 13½% water by weight). If the moisture threshold isexceeded, the operator could remove the sample and dry it to anacceptable moisture level before packaging it for shipment.

System 10 does not automatically open the hinged bottom door 125 onbucket 122 (see FIG. 50) when it determines seed in bucket 122 is readyto bag. Rather, it sends a signal to the operator that the seed sampleis accumulated in bucket 122 and ready to bag. The signal is a blinkinglight. Other types of signals are possible. System 10 waits for aresponse from the operator. The operator can acknowledge the signal, beprompted to have a bag or bags in place, and then affirmatively informsystem 10 that the appropriate bag or bags is/are in place (e.g. byhitting a key or pushing a button (e.g. 22 mm illuminated push-buttonswitch, model HW1L-M4F11Q-G-24V from IDEC Corporation of Sunnyvale,Calif.) or touch screen). Optionally, a microswitch could sense that abag is in place and ready for filling. Controller 12 would then operatebagging product actuator PN12 after weight and moisture measurements areobtained and the product would fall by gravity through bagging funnel126 and into a bag mounted to bag holder 127.

Several different sized bag holders 127 are mounted to bagging station37 under funnel 126, to accommodate different sized bags, as shown.

Bagging station 37 also can bag seed or materials not selected in theprocessing cycle of system 10, the “dirty” material. Such material canbe conveyed from other parts of system 10 pneumatically to dirty baggingcyclone 121 where it would accumulate in dirty bagging bucket 132. Itcan either be selectively pneumatically conveyed to another location(such as a dirty product dump 133—see FIG. 15) or actuator PN13 can beoperated by controller 12 to open a bottom door 134 (FIG. 53) in bucket132, and the dirty product would fall by gravity into dirty productfunnel 135 and into a bag mounted to dirty product bag holder 136.

System 10 therefore allows decisions to be executed, such as where“dirty” seed is sent. It is many times desirable to save “dirty” seed,because it could contain acceptable seed which then would be availableif the good sample is not enough or for warehousing for later use.

Also, it is possible to configure system 10 to add in one or moreadditional stations or functions prior to bagging of samples. Asdiscussed earlier, for example, another air transport could be added toconvey a sample to a non-destructive evaluator like disclosed in Wrightet al. U.S. Pat. No. 5,991,025, or for other processing or measurements.

As shown in FIGS. 1 and 6, a label printer 42 (e.g. Model 105SE fromZebra, Vernon Hills, Ill.), controlled by PC 14, could print and apply abar-coded label with desired information to bag 20A.

The information on label 22, and a corresponding database, could be inthe form of Table 2.

TABLE 2 Entries Table Data Database field Field 1 search barcode:      Field 2 weight:       Field 3 moisture:       Field 4 seed count:      Field 5 sample too wet:       Field 6 box ID:       Field 7 shell time &date:       Field 8 duplicate sample:       Field 9 duplicate sequencenumber Field 10 dirty bag saved Field 11 contact e-mail Field 12 <userdefined> (as many fields as needed) Box Table Field 1 Box ID Field 2 BoxFull Field 3 sample count Field 4 ship weight Field 5 date shipped Field6 <user defined>

Other information, of course, can be contained in such database tables,including specific test plot identification and location, seed inventorynumber(s), experiment number(s), etc.

PC 14 can use a program to match up certain columns in its localdatabase 37 with what is desired to be printed in label 22. For example,commercially available program Bar Tender from Seagull Scientific, Inc.of Bellevue, Wash. can be used for this purpose. It makes it easy toformat the label relative the database. Therefore, other or differentinformation could be printed on label 22, as desired. Normally, label 22will always have a unique ID of the sample that can be correlated to thelocal and/or central database.

Label could be part bar code and part human readable. For example, itcould contain special information such as warnings, that would be humanreadable. One example is that it could explicitly state that thecontents of the package contain genetically modified seeds, which haveto be handled carefully.

Labels for bags of “good” product and “dirty” product could differ.

Software of system 10 thus creates a label for each validated samplethat arrives at and is ready for bagging. Printer 42 can also create abox label 45 for box, which would essentially be a packing label for box44, listing by some identification, everything to be placed in box 44.Also, because weight of each sample is known (along with weight of theempty bags), system 10 can accumulate total weight for multiple packagedsamples and alert the operator when a total weight threshold is reached(for example, certain air freight or overnight air express companieshave a maximum weight limit per box (e.g. 70 lbs.).

As shown in the Figures, and described herein, system 10 presents acombination of apparatus that can receive ear corn 19, automaticallyprocess it, and discharge it into bags 20. Within system 10, componentsautonomously move the ear corn or seed corn from station to station.Additionally, system 10 instructs each station and the conveyingcomponents to perform their respective operations.

Overall, samples with approximately 2000 corn seeds take on the order of40 seconds per sample through system 10.

Additionally, as illustrated at FIG. 1, one or more automatic messagecan be generated and sent (e.g. via an email server such as are known)by system 10 after processing of a sample. For example, PC 14 could usean application such as Microsoft Outlook and its MAPI function toautomatically send emails to a designated person(s) notifying them ofthe date a certain sample had been processed and its count. Such personsthus are notified what to expect. The designated persons could be a keycontact for the experiment, a customer/client of the plant breeder, orin-house personnel. System 10 can evaluate whether the sample meets arequest from the central database. Other information or uses of theinformation about samples in system 10 of course are possible. Automaticfacsimile, paging, or other notifications are possible.

F. Option, Alternatives, and Features

The included preferred embodiment is given by way of example only andnot by way of limitation to the invention which is solely described bythe claims herein. Variations obvious to one skill in the art will beincluded within the invention defined by the claims.

For example, system 10 could be configured to provide just one or just acouple of functions. Use of color sorting alone will decrease labor andincrease throughput. Use of an NIR spectrometry alone as adiscriminator, would allow quick and accurate sorting based on, forexample, high oil content.

Or, some functions could be eliminated or combined. For example,sometimes the cleaning function may not be necessary. By way of anotherexample, cleaning and color sorting might be combined in one station.

For example, with soybeans, no shelling is needed. With soybeans, athresher is used instead of a sheller. The thresher used to receiveplants and then separate the grain or seed from the straw. Cleaningcould be performed with a spiral separator. Sorting might be done withan NMR device discriminating seeds based on oil content. Selected seedscould be placed into wells on trays instead of into bags.

Computer 14 and controller 12 might be combined into one station, deviceor processor.

The ability to automate all or part of the process can be combined withthe automated labeling and bar code scanning processes to keep controlof inventory and shipping.

Alternatives to bar codes on tags or labels could possibly be used. Oneexample is radio frequency (rf) identification or tags, such as arecommercially available. Any type of digitizable ID that can be machineread may be possible.

Cleaner 30 could be a vision sorter using machine vision to determinesize and/or shape of individual seeds and accept or discard them basedon programmed parameters. Machine vision could also perform the colorsorting function. Other non-destructive techniques, like those mentionedearlier, could be used to discriminate between seeds on other bases,such as oil content, constituents, etc.

System 10 can include automatic dust collection. Using the ability tocreate vacuum, system 10 could vacuum up dust or lighter debris insystem 10 and discharge it, or convey it to a discard bin for system 10.

System 10 could also be configured to run a clean out or unload cycle.System would run a conventional sequence of processes but without asample to clean out lingering debris or seeds from system 10.

System 10 could optionally be used for any of its functions. Forexample, it could be used for a seed counter alone. Likewise, just forany of the other functions, or, for any combination of functions. Forexample, it could be used as a sheller/bagger, or a size sorter/bagger,or as a sheller/size sorter/color sorter.

Alternative conveyors could be used. Examples might include bucketconveyors or augers. Others are possible.

Optionally, sensors could be used at locations throughout system 10 todetect the presence of a sample and be used by controller 12 to processeach sample, as opposed to using primarily timing to control conveyanceand operations of each station on a sample.

System 10 could also be programmed to automatically adjust the settingsof various stations based upon monitoring of what occurs with a sampleat a first station, or based on information in the harvest tag. Forexample, if the time to shell a sample were measured at sheller 28,system 10 could be configured to change its timing for succeedingstations based on shelling time. If a relatively long shelling time isobserved, system 10 would assume a relatively large sample quantity andperhaps lengthen the time allotted to operation of cleaner 30.

The concept of tracking individual sets of seed or samples of seedthrough system 10 can be used to maintain spatial separation of one setor sample of seed from other seeds. One can establish, by empiricaltesting, a timing regime wherein each set of seed has a certain amountof time in or at each station of system 10. Because the state of thecontrol gates that control when seed can move in and out of each stationis known, controller 12 can keep track of which gates have opened andclosed at which part of system 10 for each set or sample, and thussystem 10 via controller 12 essentially knows where each seed set orsample is at in system 10. Empirical testing for a given type and/orvolume and/or characteristics of seed can reveal how much time is neededin each station for the set of seeds to be completely processed.Controller 12 can be programmed to give that amount of time, or perhapsa little more, for its relevant station, before letting the next set ofseeds or sample to begin entry into that station. Thus, system 10 can beprogrammed in a timing regime in a manner which has shown to allowacceptable processing with clean out for each station until a succeedingsample is allowed to progress into that station. The amount of timeshould be minimized while maintaining sufficient time to ensure reliablecompletion of processing and clean out. Thus, even without positionsensors, spatial separation of plural seed samples progressing throughsystem 10 can be maintained.

1. A method of handling sets of soybean seed comprising: (a) validatingthe identity of a previously harvested soybean plant sample; (b)threshing the soybean plant; (c) autonomously sorting the threshedsoybean seeds based on characteristics automatically non-destructivelysensed from the soybean seeds; (d) maintaining, in isolation from otherseeds, a selected set of the sorted seeds; and (e) accumulating theisolated set of sorted seeds for further use.
 2. The method of claim 1wherein the characteristics are selected from the set comprising weight,moisture, chemical properties, physical properties, and temperature. 3.The method of claim 1 wherein the sensing is by spectroscopy.
 4. Themethod of claim 3 where the spectroscopy is near infrared spectroscopy.5. The method of claim 1 wherein the sensing is by non-destructiveanalysis.
 6. The method of claim 1 further comprising cleaning the seed.7. The method of claim 1 further comprising sizing the seed prior tosorting.
 8. The method of claim 7 wherein the sizing is by shape of theseed.
 9. The method of claim 1 further comprising counting the seed. 10.The method of claim 9 further comprising bagging a pre-determinedquantity of the counted seed.
 11. The method of claim 1 furthercomprising automatically controlling and tracking the conveyance of thesoybean seed during the process.